US20120252325A1 - Systems and methods for fluidizing an abrasive material - Google Patents
Systems and methods for fluidizing an abrasive material Download PDFInfo
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- US20120252325A1 US20120252325A1 US13/436,354 US201213436354A US2012252325A1 US 20120252325 A1 US20120252325 A1 US 20120252325A1 US 201213436354 A US201213436354 A US 201213436354A US 2012252325 A1 US2012252325 A1 US 2012252325A1
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- Prior art keywords
- distributor
- abrasive
- flow passage
- gas
- end portion
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
- B24C1/04—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for treating only selected parts of a surface, e.g. for carving stone or glass
- B24C1/045—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for treating only selected parts of a surface, e.g. for carving stone or glass for cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C3/00—Abrasive blasting machines or devices; Plants
- B24C3/02—Abrasive blasting machines or devices; Plants characterised by the arrangement of the component assemblies with respect to each other
- B24C3/04—Abrasive blasting machines or devices; Plants characterised by the arrangement of the component assemblies with respect to each other stationary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C7/00—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts
- B24C7/0007—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a liquid carrier
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C7/00—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts
- B24C7/0007—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a liquid carrier
- B24C7/003—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a liquid carrier with means for preventing clogging of the equipment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C7/00—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts
- B24C7/0007—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a liquid carrier
- B24C7/0038—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a liquid carrier the blasting medium being a gaseous stream
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C7/00—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts
- B24C7/0084—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a mixture of liquid and gas
Definitions
- the present disclosure is directed generally to abrasive jet systems, and more particularly to abrasive jet systems and methods for fluidizing an abrasive material for use with an abrasive water jet (AWJ).
- AWJ abrasive water jet
- the resulting water jet is discharged from the orifice at a velocity that approaches or exceeds the speed of sound.
- the liquid most frequently used to form the jet is water, and the high-velocity jet may be referred to as a “water jet,” or a “waterjet.”
- Abrasives can be added to the water jet to improve the cutting power of the water jet. Adding abrasives to the water jet produces an abrasive-laden water jet referred to as an “abrasive water jet” or an “abrasive jet.” To produce an abrasive jet, the water jet passes through a mixing region in a nozzle.
- the abrasives can have grit mesh sizes ranging between approximately #36 and approximately #320, as well as other smaller and larger sizes.
- the abrasive can be a particulate matter under atmospheric (ambient) pressure or pressurized in an external hopper. The abrasive can be conveyed through a metering orifice via a gravity feed or a pressurized feed from the hopper.
- a quantity of abrasive regulated by the meeting orifice is entrained into the water jet in the mixing region.
- Typical abrasives include garnet and aluminum oxide. The exceedingly fine sizes of the particulates can create difficulty in delivering a uniform, reliable quantity of the abrasive material.
- FIG. 2 an isometric view of an abrasive jet system configured in accordance with an embodiment of the disclosure.
- FIG. 3 is an enlarged side view of a portion of the abrasive jet system of FIG. 2 schematically illustrating a fluidizing assembly configured in accordance with an embodiment of the present disclosure.
- FIG. 4 is an isometric side perspective view of an abrasive jet subassembly including a distributor or fluidizer system configured according to an embodiment of the present disclosure.
- FIG. 6 is a cross-sectional isometric side view of components of the fluidizing assembly of FIG. 5 .
- FIG. 7A is a cross-sectional isometric side view of a distributor configured in accordance with an embodiment of the present disclosure.
- FIG. 7B is an isometric end view of the distributor of FIG. 7A .
- FIG. 8A is an isometric view of a collector configured in accordance with an embodiment of the disclosure.
- FIG. 8B is a cross-sectional isometric side taken substantially along lines 8 B- 8 B in FIG. 8A .
- FIG. 9 is an isometric view of an abrasive jet system including a schematically illustrated control mechanism configured in accordance with an embodiment of the present disclosure.
- FIG. 10 is a flow diagram of a process for operating an abrasive jet system in accordance with an embodiment of the disclosure.
- abrasive jet systems for cutting or otherwise processing materials, including abrasive jet systems using abrasive particulate materials.
- abrasive jet systems as disclosed herein can be used with a variety of suitable working fluids or liquids to form the fluid jet.
- abrasive jet systems configured in accordance with embodiments of the present disclosure can include working fluids such as water, aqueous solutions, paraffins, oils (e.g., mineral oils, vegetable oil, palm oil, etc.), glycol, liquid nitrogen, and other suitable abrasive jet cutting fluids.
- water jet or “waterjet” as used herein may refer to a cutting jet formed by any working fluid associated with the corresponding abrasive jet system, and is not limited exclusively to water or aqueous solutions.
- water jet or “waterjet” as used herein may refer to a cutting jet formed by any working fluid associated with the corresponding abrasive jet system, and is not limited exclusively to water or aqueous solutions.
- suitable working fluids can be used with any of the embodiments described herein.
- air other suitable gases can be used with any of the embodiments described herein.
- a fluidizing system can deliver particulates such as fine powders and abrasive materials at relatively low rates to a nozzle assembly to form an abrasive water jet (AWJ).
- the abrasive material can be a garnet, such as a #320 mesh garnet that passes through a distributor of a fluidizing system. In other embodiments, however, the abrasive material can include other suitable materials and sizes.
- the fluidizing system can use a controlled air stream, such as a pulsating air stream, to fluidize a portion of an accumulation of abrasives that are adjacent to a metering orifice in an end portion of the distributor.
- the pulsed air flow through the gas flow passages can also prevent the abrasive material from bridging otherwise resisting flow through the metering orifice. Once the abrasive material flows through the metering orifice it can pass to a collector and eventually travel to an abrasive jet nozzle assembly to be combined with a working fluid to form the abrasive jet.
- the fluidizer system can also include an abrasive container or hopper that feeds the abrasive to the accumulation site proximate to the distributor.
- the fluidizing system can also include one or more aerators located in the hopper and configured to mix air with the abrasive material to maintain a uniform amount of entrained air in the abrasive over time.
- the aerators can also break down cavities and/or or “rat holes” that may form within the abrasive material in the hopper.
- Fluidization as used herein generally refers to passing a pressurized gas through a body of collected or accumulated particulate material, such as an abrasive material. With sufficient pressure, the pressurized gas causes the particulate material to behave as a fluid, or to at least approximately behave as a fluid.
- the fluidizing system of the present disclosure is configured to at least partially fluidize the abrasive material by passing pressurized air, such as pulsed pressurized air, through a quantity of the abrasive material accumulated proximate to an end portion of a distributor (e.g., an accumulation of abrasives collected in a settling tube or in a hopper coupled to the distributor).
- the air pulses can at least partially cause fluidization in the abrasive material.
- the diameter of the orifice 105 can be less than or greater than 0.007 inch.
- Pressurized water passes through the orifice 105 , forming a fluid or water jet 110 .
- the nozzle assembly 100 also includes an abrasive supply conduit 120 that conveys abrasives or particles to a mixing region 115 (alternatively referred to as a mixing cavity 115 ).
- the abrasives are mixed with the water jet 110 in the mixing region 115 , thereby forming an abrasive jet.
- the abrasive jet is conveyed through the axial passage 150 of the mixing tube 145 before being expelled from the mixing tube 145 .
- the abrasives can include garnet, aluminum oxide, baking soda, sugars, salts, ice particles, or other suitable abrasive particles.
- FIG. 3 is an enlarged view of a portion of the abrasive jet system of FIG. 2 , schematically illustrating a fluidizing system 300 configured in accordance with an embodiment of the disclosure and in relation to the nozzle assembly 100 , the abrasive container 230 and the abrasive supply conduit 120 .
- the fluidizing system 300 is operably coupled to a distal end portion of the abrasive supply conduit 120 .
- the fluidizing system 300 is also coupled to an abrasive feed conduit or drop tube 314 extending from the abrasive container 230 to convey abrasives 235 to the abrasive supply conduit 120 via the fluidizing system 300 .
- the fluidizing assembly 300 is configured to fluidize, disturb, unsettle, agitate, or otherwise mix the abrasive material 235 before the abrasive material enters the nozzle assembly 100 .
- the abrasive material 235 can include such small particles that the abrasive material 235 tends to clump or pack, even under ambient pressure and humidity conditions.
- the fluidizing system 300 can direct a series of pressurized pulses of air at predetermined locations to break up any packed portions or to prevent bridging and “rat holes” in the abrasives 235 before passing the abrasives 235 onward to the nozzle assembly 100 .
- FIG. 4 is a side perspective view of an abrasive jet system 401 including a fluidizer system 400 configured in accordance with embodiments of the present disclosure.
- the system 401 includes an abrasive container or hopper 402 , a material director 404 within the hopper 402 , hopper outlets or exit ports 406 , hopper connector or drop tubes 414 leading to the fluidizer system 400 , and a collector 420 downstream from the fluidizer system 400 .
- the collector 420 is coupled to the abrasive supply conduit 120 and configured to direct the abrasive material 235 to a nozzle assembly 100 .
- the material director 404 can be a sloped plate positioned within the hopper 402 and configured to direct the abrasive material 235 toward the exit ports 406 .
- the drop tubes 414 can be flexible, plastic tubes that engage corresponding fluidizer assemblies 418 (identified individually as a first fluidizer assembly 418 a and a second fluidizer assembly 418 b ) of the fluidizer system 400 .
- the hopper 402 , material director 404 , exit ports 406 , and drop tubes 406 can be made of an abrasion-resistant material such as polyurethane or another suitable material.
- the fluidizer system 400 can also include aerators 408 positioned within the hopper 402 and operably coupled to the air pressurizer 410 via corresponding gas delivery lines 483 (identified individually as a first gas delivery line 483 a and a second gas delivery line 483 b ).
- the aerators 408 can comprise nozzles 409 (identified individually as a first nozzle 409 a and a second nozzle 409 b ) positioned proximate or over the corresponding exit ports 406 .
- the fluidizer system 400 can also include a burst solenoid assembly 424 and a fluidizer solenoid assembly 426 , each of which is connected to the air pressurizer 410 by associated pressurized air delivery lines (not shown).
- the burst solenoid assembly 424 and the fluidizer solenoid assembly 426 are configured to deliver pulsed air flow and can be connected to the corresponding fluidizer assemblies 418 by gas delivery lines 430 .
- any suitable air pulse generator can be used in place of solenoid units.
- a single air pulse generator or other pressurized air source can be used rather than the burst solenoid assembly 424 and the fluidizer solenoid assembly 426 .
- the delivery lines 430 from the burst solenoid assembly 424 are connected to the delivery lines 430 frim the fluidizer solenoid assembly 426 with a “T” joint 432 .
- the burst solenoid assembly 424 and fluidizer solenoid assembly 426 each comprise two solenoid valves that are individually connected to a corresponding fluidizer assembly 418 .
- the controller 434 is configured to direct various portions of the system 400 .
- the controller 434 can instruct the aerators 408 to convey air toward the exit ports 406 to at least partially fluidize the abrasive material 235 proximate to the exit ports 406 . Conveying air through the aerators 408 can also counter-act back pressure that may be present in the exit ports 406 and drop tubes 414 .
- the controller 434 can also instruct the burst solenoid assembly 424 and the fluidizer solenoid assembly 426 to fluidize the abrasive material 235 in the fluidizer assemblies 418 , as well as direct the abrasive valve 423 to open and deliver the abrasive material 235 to the abrasive supply conduit 120 .
- the fluidizer system 400 includes a first material path extending generally from the first exit port 406 a proximate to the first aerator 408 a , through the first drop tube 414 a , and through the first fluidizer assembly 418 a .
- the fluidizer system 400 can also include a second material path extending generally from the second exit port 406 b proximate to the second aerator 408 b , through the second drop tube 414 b , and through the second fluidizer assembly 418 b .
- the components along the first material path and the second material path are substantially similar.
- the fluidizer system 400 can include three or more material paths, which may be substantially similar to the first and second material paths.
- the fluidizer system 400 can be retrofit to an existing waterjet or other appropriate assembly.
- the controller 434 can individually control the components along each of the material paths. For example, the controller 434 can alternate operation of the components along the two or more paths. In some embodiments, the controller 434 can operate the components of the first path for a brief time period (e.g., one second), then operate the components of the second path for the same brief time period. Moreover, the controller 434 can operate the components of the first and second paths 180° out of phase. Alternating operation of components of the first and second paths can improve the fluid flow of the abrasive material 235 through the first and second paths. The abrasive material 235 from the first and second paths can be diverted to disparate destinations, or to the same destination. In other embodiments, however, the controller 434 can operate the components along the first and second material paths simultaneously.
- a brief time period e.g., one second
- the controller 434 can operate the components of the first and second paths 180° out of phase. Alternating operation of components of the first and second paths can improve the fluid flow of the abras
- FIG. 5 is a cross-sectional isometric side view of one of the fluidizer assemblies 418 , the abrasive valve 423 , and a portion of the abrasive delivery conduit 120 according to embodiments of the present disclosure.
- the fluidizer assembly 418 includes a filter holder, distributor coupler, or connector 502 operably coupled to a distributor 506 .
- the fluidizer assembly 418 also includes a housing or manifold 510 coupled to the distributor 506 .
- the housing 510 can comprise a cylindrical member configured to engage an external surface of the distributor 506 .
- the housing 510 can include an air inlet port 511 that is in fluid communication with a corresponding air inlet port 508 in the distributor 506 .
- the filter holder 502 can comprise a cylindrical member having a particle flow passage or internal bore 503 through which the abrasive material 235 flows during use.
- the internal bore 503 of the filter holder 502 can act as a settling tube configured to receive the abrasive material 235 and be made of an abrasion-resistant material, such as polyurethane or another suitable material.
- An upper portion 502 a of the filter holder 502 can engage a corresponding drop tube 414 ( FIG. 4 ), and lower portion 502 b of the filter holder 502 can engage the distributor 506 .
- the filter holder 502 has a degree of flexibility and the lower portion 502 b can snap or slide onto the distributor 506 .
- other suitable attachment mechanisms are possible, including threaded and o-ring fastening mechanisms.
- the distributor 506 can also comprise a cylindrical member having a material flow passage or internal bore 507 , and can include an air inlet 511 in fluid communication with air flow passages or conduits 509 .
- the distributor 506 can be made of a metal such as aluminum, or a plastic such as polyurethane.
- the distributor 506 is made of an electrically conductive material such as aluminum and electrically grounded to another portion of the fluidizer assembly 418 to disperse any static electricity that can accumulate in the abrasive material 235 as a result of the fluidizing operation.
- the distributor 506 also includes a metering orifice 501 generally axially or centrally aligned with the bore 503 .
- the diameter of the metering orifice 501 is configured to permit the abrasive material 235 to pass through the metering orifice 501 at a desired rate.
- the diameter of the metering orifice 501 can therefore depend on the dimensions and type of the abrasive material 235 , as well as other predetermined parameters of a cutting or other procedure for the abrasive material 235 .
- the fluidizer assembly 418 can also include a filter assembly 513 comprising a filter 514 and a screen 518 positioned between the filter holder 502 and the distributor 506 .
- the filter 514 can be a woven polyurethane having openings or holes configured to prevent the abrasive material 235 from passing through the filter 514 .
- the holes are approximately 5 microns across. In other embodiments, however, the holes can be larger or smaller than 5 microns.
- the screen 518 can be a rigid member positioned between the filter 514 and the filter holder 502 . Further details of the filter assembly 513 are described in detail below with reference to FIG. 6 .
- the air inlet 508 of the housing 510 is connected to one of the air delivery lines 430 ( FIG. 4 ) and configured to receive pressurized air from the burst solenoid assembly 424 and/or the fluidizing solenoid assembly 426 .
- the air can be pulsed or flow at a constant rate or pressure. The pulsed air from the solenoid assemblies 424 , 426 moves through the air inlet 508 of the housing 510 , and enters the air inlet 511 of the distributor 506 .
- the air can then travel through the flow passages 509 and through the filter assembly 513 to fluidize the abrasive material 235 accumulated at or near the filter assembly 513 to facilitate passage of the abrasives material 235 through the metering orifice 501 .
- the filter assembly 513 can prevent the abrasive material from flowing back down the air flow passages 509 .
- FIG. 6 is a cross-sectional view of the filter holder 502 , filter assembly 513 , distributor 506 , and housing 510 of FIG. 5 .
- the screen 518 includes screen sections 518 a divided by separating members 518 b extending radially outwardly from a central opening 521 .
- the screen 518 can be a mesh plate without the separating members 518 b .
- the screen sections 518 a can be a of fine mesh, such as a Dutch weave made of stainless steel and having holes of approximately 0.004 inch. In other embodiments, however, the holes can be greater or less than approximately 0.004 inch.
- the air inlet 508 of the distributor 506 can be a channel or groove extending circumferentially around an exterior surface of the body the distributor 506 .
- the air flow passages 509 are in fluid communication with the air inlet 508 and extend from the air inlet 508 in a directly generally parallel with a longitudinal axis A of the distributor 506 to reach the filter assembly 513 .
- the air inlet 508 can deliver pressurized air through the distributor 506 to the filter assembly 513 via the flow passages 509 to fluidize the abrasive material 235 accumulated at the end portion of the distributor 506 .
- FIG. 7A is a cross-sectional isometric side view of the distributor 506 of FIG. 6 .
- the distributor 506 can comprise a cylindrical body with a central bore 507 axially aligned with a metering orifice 501 .
- the distributor 506 also includes a plurality of flow passages 509 radially spaced apart from the bore 507 and extending in a direction generally parallel to a longitudinal axis A of the distributor 506 .
- the distributor 506 can include eight flow passages 509 spaced evenly around the distributor 506 . In other embodiments, however, the distributor 506 can include a greater or lesser number of flow passages 509 .
- the flow passages 509 can terminate as exit openings 702 at an end portion 704 of the distributor 506 .
- the end portion 704 can be configured to directly contact the filter assembly 513 ( FIG. 6 ).
- the end portion 704 of the distributor 506 can also include grooves or channels 706 extending radially outwardly from the metering orifice 506 a to a corresponding exit opening 702 .
- each groove 706 can have a generally tapered depth from the exterior surface of the end portion 704 that decreases from the metering orifice 506 a as the groove 706 extends toward the corresponding exit opening 702 .
- each groove can have a generally constant depth or a depth that tapers in an opposite direction than that shown in FIG.
- exit openings 702 can be approximately 0.013 inch in diameter, and the grooves 706 can be approximately 0.02 inch wide and approximately 0.03 inch deep. In other embodiments, other dimensions and configurations can be used.
- FIG. 7B is an isometric end view of the end portion 704 , the exit openings 702 , and the grooves 706 of the distributor 506 according to embodiments of the present disclosure.
- the end portion 704 includes four equally spaced apart grooves extending radially outwardly from the metering orifice 506 a to individual corresponding exit openings 702 .
- the end portion 704 can include a greater or lesser number of grooves 706 .
- other configurations of the grooves and/or exit openings 702 are possible as well.
- other embodiments of the distributor can have different numbers of exit openings 702 and/or grooves 706 than those shown in FIG. 7B .
- FIG. 8A is an isometric view of the collector 420 of FIG. 4
- FIG. 8B is a cross-sectional isometric side view taken substantially along lines 8 B- 8 B of FIG. 4
- the collector 420 includes a body 802 that can be made of an abrasion-resistant material such as polyurethane and having a funnel surface 804 sloping toward an outlet opening 806 .
- the body 802 can be made from a metallic material, such as aluminum.
- the outlet opening 806 can be aligned with or otherwise coupled to an abrasive supply conduit for receiving the abrasive material after passing through the fluidizing assembly 418 and the metering orifice 501 .
- the funnel surface 804 can have any appropriate slope that facilitates passage of the abrasive material and prevents the abrasive material from collecting. If the abrasive material 235 is allowed to collect, it may reach the water jet 110 in a non-uniform manner and impair the quality of a cut.
- FIG. 9 is an isometric view of the abrasive jet system 401 ( FIG. 4 ) including a schematically illustrated control mechanism 900 configured in accordance with embodiments of the present disclosure.
- the control mechanism 900 includes flow meter 904 and a pressure gauge 908 associated with the air pressurizer 410 .
- the air pressurizer 904 is pneumatically connected to the aerators 408 , the burst solenoid assembly 424 , and the fluidizer solenoid assembly 426 to supply air or other suitable gases to each of these assemblies for fluidizing the corresponding abrasive material.
- the air pressurizer 410 can also be pneumatically connected to the abrasive valve 423 .
- the control mechanism 900 includes a controller 912 coupled to a programmable logic controller (PLC) 916 .
- the PLC 916 is configured to receive a “pump on” or gas flow signal 918 and/or an “abrasive on” or abrasive flow signal 920 from the controller 912 .
- the PLC 916 can also be operably coupled to the air pressurizer 410 to transmit various control signals to the air pressurizer 410 during operation.
- the PLC 916 can transmit a fluidizer solenoid signal 924 , a burst solenoid signal 926 , and/or an abrasive valve signal 923 to the air pressurizer 410 .
- the controller 916 and the PLC 916 can control the air pressurizer 410 to convey air flow from the fluidizer solenoid assembly 426 to the fluidizer assembly 418 , air flow from the burst solenoid assembly 424 to the fluidizer assembly 418 , and/or air flow to the abrasive valve 423 to control abrasive flow.
- the PLC 916 can in turn instruct the air pressurizer 410 to deliver air to the abrasive valve 423 via an abrasive signal 991 .
- the controller 912 issues the “pump on” or gas flow signal 918
- the PLC 916 can in turn instruct the air pressurizer 410 to deliver air to the aerators 408 via an aerator signal 990 , as well as to deliver air to the burst solenoid assembly 424 via burst signal 992 .
- the burst solenoid assembly 424 in response to the burst signal 992 , can deliver a strong but transient burst of air to the fluidizer assembly 418 to unsettle the abrasive material 235 that has collected on the filter assembly 513 ( FIGS. 4 and 5 ).
- the burst solenoid assembly 424 can deliver a 25 psi burst of air for approximately 0.5 second to initially loosen or otherwise disturb the abrasive material 235 .
- the initial burst can be at a higher or lower pressure, as well as for a shorter or longer duration.
- PLC 916 can instruct the fluidizer solenoid assembly 426 to deliver pulses of air through the same airway as the initial burst via a pulse signal 994 to at least partially fluidize the abrasive material.
- the pulses of air can be at approximately 1.5 psi at a frequency of approximately 50 Hz.
- the throughput of the pulsed air flow from the fluidizer solenoid assembly 426 can be approximately 10 ft3/h. In other embodiments, however, the pulses of air can be at higher or lower pressures, as well as at higher or lower frequencies.
- a single air pulse generator or solenoid can provide the various pulses of air flow.
- a single air pulse generator can provide an initial pulse or burst of air flow to the fluidizer assembly 418 , followed by one or more subsequent pulses or bursts of air flow to the fluidizer assembly 418 .
- the initial pulse of air can be at a higher pressure and/or for a different duration than the one or more subsequent bursts of air.
- the initial burst of air can be at the same pressure or a lower pressure than the one or more subsequent bursts of air, as well as for the duration as the individual one or more bursts of air.
- These routines can be executed by the PLC 916 when the controller 912 sends one or more signals to convey abrasive material and/or air flow. Fluidizing the abrasive material with an initial burst followed by sustained pulses causes the abrasive material to evenly or uniformly flow from the abrasive container 230 to the corresponding nozzle assembly 100 ( FIG. 3 ).
- FIG. 10 is a flow diagram of a method or process 1000 for operating an abrasive jet system in accordance with an embodiment of the disclosure.
- the process 1000 includes conveying gas through a gas flow passage of a distributor to an accumulation of particles proximate to an end portion of the distributor (block 1002 ).
- Conveying gas through the gas flow passage can include at least partially fluidizing the particles proximate to a metering orifice in the end portion of the distributor that is configured to receive particles from the accumulation of particles.
- the gas flow passage can exit the end portion of the distributor at a location spaced apart from the metering orifice.
- conveying gas through the gas flow passage includes conveying gas through the gas flow passage at a first pressure and subsequently conveying gas through the gas flow passage at a second pressure that is different than the first pressure.
- the second pressure can be less than the first pressure. In other embodiments, however, the second pressure can be greater than the first pressure, or the same as the first pressure.
- conveying gas through the gas flow passage at the first pressure can also include conveying at least one pulse of gas at the first pressure and conveying gas through the gas flow passage at the second pressure can also include conveying at least one pulse of gas at the second pressure.
- the first pulse can be for a different duration (e.g., longer or shorter) than the subsequent at least one pulse. In other embodiments, the duration of these pulses can be the same.
- conveying gas through the gas flow passage can include conveying gas through a plurality of gas flow passages that are radially spaced apart from the metering orifice and that extend in a direction generally parallel to a longitudinal axis of the distributor. Additionally, conveying gas through the gas flow passage can further include conveying gas through a screen assembly positioned at the end portion of the distributor. Moreover, in certain embodiments the accumulation of particles can be in an abrasive container and/or in a connector operably coupled to the distributor.
- the accumulation of particles can be a first accumulation of particles in a connector extending between the distributor and an exit from abrasive container, and the process 1000 can further include conveying gas through an aerator to a second accumulation of particles proximate to the exit in the abrasive container.
- the method also includes conveying particles from the accumulation of particles to a nozzle assembly via the distributor, wherein the particles pass through the metering orifice (block 1004 ).
- conveying particles from the accumulation of particles comprises opening a particle flow valve downstream from the distributor. After passing through the distributor, the particles can be combined with fluid to form an abrasive jet in a nozzle assembly.
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Abstract
Description
- This disclosure claims priority to U.S. Provisional Patent Application No. 61/471,039, filed Apr. 1, 2011, entitled “SYSTEMS AND METHODS FOR FLUIDIZING AN ABRASIVE MATERIAL,” which is incorporated herein by reference in its entirety. This disclosure also incorporates by reference in its entirety U.S. patent application Ser. No. [Attorney Docket Number 61234.8014.US00], entitled “PARTICLE-DELIVERY IN ABRASIVE JET SYSTEMS,” filed concurrently herewith.
- The present disclosure is directed generally to abrasive jet systems, and more particularly to abrasive jet systems and methods for fluidizing an abrasive material for use with an abrasive water jet (AWJ).
- Abrasive jet systems that produce high-velocity, abrasive-laden fluid jets for accurately and precisely cutting various materials are well known. Abrasive jet systems typically function by pressurizing water (or another suitable fluid) to a very high pressure (e.g., up to 90,000 pounds per square inch (psi) or more) by, for example, a high-pressure pump connected to an abrasive jet cutting head. The pressurized water is forced through an orifice at a very high speed (e.g., up to 2500 feet per second or more). The orifice forms the water jet. The orifice is typically a hard jewel (e.g., a synthetic sapphire, ruby, or diamond) held in an orifice mount. The resulting water jet is discharged from the orifice at a velocity that approaches or exceeds the speed of sound. The liquid most frequently used to form the jet is water, and the high-velocity jet may be referred to as a “water jet,” or a “waterjet.”
- Abrasives can be added to the water jet to improve the cutting power of the water jet. Adding abrasives to the water jet produces an abrasive-laden water jet referred to as an “abrasive water jet” or an “abrasive jet.” To produce an abrasive jet, the water jet passes through a mixing region in a nozzle. The abrasives can have grit mesh sizes ranging between approximately #36 and approximately #320, as well as other smaller and larger sizes. The abrasive can be a particulate matter under atmospheric (ambient) pressure or pressurized in an external hopper. The abrasive can be conveyed through a metering orifice via a gravity feed or a pressurized feed from the hopper. A quantity of abrasive regulated by the meeting orifice is entrained into the water jet in the mixing region. Typical abrasives include garnet and aluminum oxide. The exceedingly fine sizes of the particulates can create difficulty in delivering a uniform, reliable quantity of the abrasive material.
- The resulting abrasive-laden water jet is then discharged through a nozzle tip that is adjacent to a workpiece. Such abrasive jets can be used to cut a wide variety of materials. For example, the abrasive jet can be used to cut hard materials (such as tool steel, aluminum, cast-iron armor plate, certain ceramics and bullet-proof glass) as well as soft materials (such as lead). A typical technique for cutting with an abrasive jet is to mount a workpiece to be cut in a suitable jig or other means for securing the workpiece into position. The abrasive jet can be directed onto the workpiece to accomplish the desired cutting, generally under computer or robotic control.
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FIG. 1 is a cross-sectional side view of a portion of an abrasive jet nozzle assembly configured in accordance with an embodiment of the disclosure. -
FIG. 2 an isometric view of an abrasive jet system configured in accordance with an embodiment of the disclosure. -
FIG. 3 is an enlarged side view of a portion of the abrasive jet system ofFIG. 2 schematically illustrating a fluidizing assembly configured in accordance with an embodiment of the present disclosure. -
FIG. 4 is an isometric side perspective view of an abrasive jet subassembly including a distributor or fluidizer system configured according to an embodiment of the present disclosure. -
FIG. 5 is a cross-sectional isometric side view of a distributor or fluidizer assembly configured in accordance with an embodiment of the present disclosure. -
FIG. 6 is a cross-sectional isometric side view of components of the fluidizing assembly ofFIG. 5 . -
FIG. 7A is a cross-sectional isometric side view of a distributor configured in accordance with an embodiment of the present disclosure. -
FIG. 7B is an isometric end view of the distributor ofFIG. 7A . -
FIG. 8A is an isometric view of a collector configured in accordance with an embodiment of the disclosure. -
FIG. 8B is a cross-sectional isometric side taken substantially alonglines 8B-8B inFIG. 8A . -
FIG. 9 is an isometric view of an abrasive jet system including a schematically illustrated control mechanism configured in accordance with an embodiment of the present disclosure. -
FIG. 10 is a flow diagram of a process for operating an abrasive jet system in accordance with an embodiment of the disclosure. - This application describes various embodiments of abrasive jet systems for cutting or otherwise processing materials, including abrasive jet systems using abrasive particulate materials. For example, abrasive jet systems as disclosed herein can be used with a variety of suitable working fluids or liquids to form the fluid jet. More specifically, abrasive jet systems configured in accordance with embodiments of the present disclosure can include working fluids such as water, aqueous solutions, paraffins, oils (e.g., mineral oils, vegetable oil, palm oil, etc.), glycol, liquid nitrogen, and other suitable abrasive jet cutting fluids. As such, the term “water jet” or “waterjet” as used herein may refer to a cutting jet formed by any working fluid associated with the corresponding abrasive jet system, and is not limited exclusively to water or aqueous solutions. In addition, although several embodiments of the present disclosure are described below with reference to water, other suitable working fluids can be used with any of the embodiments described herein. Moreover, although several embodiments of the present disclosure are described below with reference to air, other suitable gases can be used with any of the embodiments described herein. Certain details are set forth in the following description and in
FIGS. 1-10 to provide a thorough understanding of various embodiments of the technology. Other details describing well-known aspects of abrasive jet systems, however, are not set forth in the following disclosure so as to avoid unnecessarily obscuring the description of the various embodiments. - According to embodiments of the present disclosure, a fluidizing system can deliver particulates such as fine powders and abrasive materials at relatively low rates to a nozzle assembly to form an abrasive water jet (AWJ). In some embodiments, the abrasive material can be a garnet, such as a #320 mesh garnet that passes through a distributor of a fluidizing system. In other embodiments, however, the abrasive material can include other suitable materials and sizes. The fluidizing system can use a controlled air stream, such as a pulsating air stream, to fluidize a portion of an accumulation of abrasives that are adjacent to a metering orifice in an end portion of the distributor. For example, the pulsed air stream can be delivered through gas flow passages extending longitudinally through the distributor and exiting the distributor at locations radially spaced apart from the metering orifice. The fluidizing system can also include a filter assembly that prevents the abrasive from back-flowing through the gas flow passages. In operation, when the flow of abrasive material is initiated, an initial pulse or burst of relatively higher pressure air flow can mobilize abrasives that have settled near the metering orifice of the end portion of the distributor. Following the initial pulse of air, a series of lower pressure pulses of air flow can create or sustain a generally fluidized state of the abrasive material. The pulsed air flow through the gas flow passages can also prevent the abrasive material from bridging otherwise resisting flow through the metering orifice. Once the abrasive material flows through the metering orifice it can pass to a collector and eventually travel to an abrasive jet nozzle assembly to be combined with a working fluid to form the abrasive jet.
- According to additional embodiments of the present disclosure, the fluidizer system can also include an abrasive container or hopper that feeds the abrasive to the accumulation site proximate to the distributor. In certain embodiments, the fluidizing system can also include one or more aerators located in the hopper and configured to mix air with the abrasive material to maintain a uniform amount of entrained air in the abrasive over time. The aerators can also break down cavities and/or or “rat holes” that may form within the abrasive material in the hopper.
- Fluidization as used herein generally refers to passing a pressurized gas through a body of collected or accumulated particulate material, such as an abrasive material. With sufficient pressure, the pressurized gas causes the particulate material to behave as a fluid, or to at least approximately behave as a fluid. In some embodiments, the fluidizing system of the present disclosure is configured to at least partially fluidize the abrasive material by passing pressurized air, such as pulsed pressurized air, through a quantity of the abrasive material accumulated proximate to an end portion of a distributor (e.g., an accumulation of abrasives collected in a settling tube or in a hopper coupled to the distributor). The air pulses can at least partially cause fluidization in the abrasive material.
- Many of the details, dimensions, angles and other features shown in the Figures are merely illustrative of particular embodiments. Accordingly, other embodiments can have other details, dimensions, angles and features. In addition, further embodiments can be practiced without several of the details described below. In the Figures, identical reference numbers identify identical, or at least generally similar, elements.
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FIG. 1 is a cross-sectional side view of a portion of an abrasivejet nozzle assembly 100 configured in accordance with an embodiment of the disclosure. In the illustrated embodiment, thenozzle assembly 100 includes a mixingtube 145 having anaxial passage 150. In some embodiments, theaxial passage 150 can have an inside diameter of at least approximately 0.015 inch (0.38 mm). In other embodiments, however, the inside diameter of theaxial passage 150 can be greater than or less than approximately 0.015 inch. Thenozzle assembly 100 also includes a fluid inlet orifice oraperture 105. In certain embodiments, the orifice can have a diameter of at least approximately 0.007 inch (0.18 mm). In other embodiments, however the diameter of theorifice 105 can be less than or greater than 0.007 inch. Pressurized water (or other suitable working fluids) passes through theorifice 105, forming a fluid orwater jet 110. Thenozzle assembly 100 also includes anabrasive supply conduit 120 that conveys abrasives or particles to a mixing region 115 (alternatively referred to as a mixing cavity 115). The abrasives are mixed with thewater jet 110 in the mixingregion 115, thereby forming an abrasive jet. The abrasive jet is conveyed through theaxial passage 150 of the mixingtube 145 before being expelled from the mixingtube 145. In certain embodiments, the abrasives can include garnet, aluminum oxide, baking soda, sugars, salts, ice particles, or other suitable abrasive particles. -
FIG. 2 is an isometric view of anabrasive jet system 200 configured in accordance with an embodiment of the disclosure and which is suitable for use with thenozzle assembly 100 ofFIG. 1 . As shown inFIG. 2 , theabrasive jet system 200 includes abase 205 and amechanism 210 for moving thenozzle assembly 100. Theabrasive jet system 200 may also include pressurized working fluid or water source, such as a pump (not shown inFIG. 2 ) that conveys highly pressurized water (e.g., from about 15,000 psi or less to about 60,000 psi or more) to thenozzle assembly 100. Theabrasive jet system 200 also includes theabrasive supply conduit 120 that conveysabrasives 235 from anabrasive container 230 to thenozzle assembly 100. In some embodiments, theabrasive jet system 200 can also include pressurized or vacuum conveyance ofabrasives 235 to thenozzle assembly 100. Additional details regarding the flow or conveyance ofabrasives 235 are described in detail below. In the illustrated embodiment, theabrasive jet system 200 can also include acontroller 215 that an operator may use to program or otherwise control theabrasive jet system 200. -
FIG. 3 is an enlarged view of a portion of the abrasive jet system ofFIG. 2 , schematically illustrating afluidizing system 300 configured in accordance with an embodiment of the disclosure and in relation to thenozzle assembly 100, theabrasive container 230 and theabrasive supply conduit 120. In the illustrated embodiment, thefluidizing system 300 is operably coupled to a distal end portion of theabrasive supply conduit 120. Thefluidizing system 300 is also coupled to an abrasive feed conduit or droptube 314 extending from theabrasive container 230 to conveyabrasives 235 to theabrasive supply conduit 120 via thefluidizing system 300. As described in detail below, the fluidizingassembly 300 is configured to fluidize, disturb, unsettle, agitate, or otherwise mix theabrasive material 235 before the abrasive material enters thenozzle assembly 100. For example, theabrasive material 235 can include such small particles that theabrasive material 235 tends to clump or pack, even under ambient pressure and humidity conditions. Thefluidizing system 300, however, can direct a series of pressurized pulses of air at predetermined locations to break up any packed portions or to prevent bridging and “rat holes” in theabrasives 235 before passing theabrasives 235 onward to thenozzle assembly 100. -
FIG. 4 is a side perspective view of anabrasive jet system 401 including afluidizer system 400 configured in accordance with embodiments of the present disclosure. Thesystem 401 includes an abrasive container orhopper 402, amaterial director 404 within thehopper 402, hopper outlets orexit ports 406, hopper connector or droptubes 414 leading to thefluidizer system 400, and acollector 420 downstream from thefluidizer system 400. Thecollector 420 is coupled to theabrasive supply conduit 120 and configured to direct theabrasive material 235 to anozzle assembly 100. The flow of theabrasive material 235 through thefluidizer system 400 can be controlled by anabrasive valve 423, which can include a plunger or other suitable valve. Theabrasive valve 423 can be pneumatically actuated via a controller 434 (shown schematically). For example, theabrasive valve 423 can be operably coupled to anair pressurizer 410 via gas delivery lines 481 (identified individually as a firstgas delivery line 481 a and a secondgas delivery line 481 b). Thehopper 402 can be a cylindrical, plastic container configured to receive theabrasive material 235. Thematerial director 404 can be a sloped plate positioned within thehopper 402 and configured to direct theabrasive material 235 toward theexit ports 406. Thedrop tubes 414 can be flexible, plastic tubes that engage corresponding fluidizer assemblies 418 (identified individually as afirst fluidizer assembly 418 a and asecond fluidizer assembly 418 b) of thefluidizer system 400. Thehopper 402,material director 404,exit ports 406, and droptubes 406 can be made of an abrasion-resistant material such as polyurethane or another suitable material. - The
fluidizer system 400 can also includeaerators 408 positioned within thehopper 402 and operably coupled to theair pressurizer 410 via corresponding gas delivery lines 483 (identified individually as a firstgas delivery line 483 a and a secondgas delivery line 483 b). Theaerators 408 can comprise nozzles 409 (identified individually as a first nozzle 409 a and a second nozzle 409 b) positioned proximate or over the correspondingexit ports 406. Thefluidizer system 400 can also include aburst solenoid assembly 424 and afluidizer solenoid assembly 426, each of which is connected to theair pressurizer 410 by associated pressurized air delivery lines (not shown). Theburst solenoid assembly 424 and thefluidizer solenoid assembly 426 are configured to deliver pulsed air flow and can be connected to thecorresponding fluidizer assemblies 418 by gas delivery lines 430. In other embodiments, however, any suitable air pulse generator can be used in place of solenoid units. Moreover, in other embodiments, a single air pulse generator or other pressurized air source can be used rather than theburst solenoid assembly 424 and thefluidizer solenoid assembly 426. In some embodiments, thedelivery lines 430 from theburst solenoid assembly 424 are connected to thedelivery lines 430 frim thefluidizer solenoid assembly 426 with a “T” joint 432. In some embodiments, theburst solenoid assembly 424 andfluidizer solenoid assembly 426 each comprise two solenoid valves that are individually connected to acorresponding fluidizer assembly 418. - During operation, the
controller 434 is configured to direct various portions of thesystem 400. For example, in response to a signal to deliver theabrasive material 235, thecontroller 434 can instruct theaerators 408 to convey air toward theexit ports 406 to at least partially fluidize theabrasive material 235 proximate to theexit ports 406. Conveying air through theaerators 408 can also counter-act back pressure that may be present in theexit ports 406 and droptubes 414. Thecontroller 434 can also instruct theburst solenoid assembly 424 and thefluidizer solenoid assembly 426 to fluidize theabrasive material 235 in thefluidizer assemblies 418, as well as direct theabrasive valve 423 to open and deliver theabrasive material 235 to theabrasive supply conduit 120. - In some embodiments, the
fluidizer system 400 includes a first material path extending generally from thefirst exit port 406 a proximate to the first aerator 408 a, through the first drop tube 414 a, and through thefirst fluidizer assembly 418 a. Thefluidizer system 400 can also include a second material path extending generally from thesecond exit port 406 b proximate to the second aerator 408 b, through thesecond drop tube 414 b, and through thesecond fluidizer assembly 418 b. In some embodiments, the components along the first material path and the second material path are substantially similar. In other embodiments, however, thefluidizer system 400 can include three or more material paths, which may be substantially similar to the first and second material paths. Moreover, thefluidizer system 400 can be retrofit to an existing waterjet or other appropriate assembly. - In embodiments including two or more material paths, the
controller 434 can individually control the components along each of the material paths. For example, thecontroller 434 can alternate operation of the components along the two or more paths. In some embodiments, thecontroller 434 can operate the components of the first path for a brief time period (e.g., one second), then operate the components of the second path for the same brief time period. Moreover, thecontroller 434 can operate the components of the first and second paths 180° out of phase. Alternating operation of components of the first and second paths can improve the fluid flow of theabrasive material 235 through the first and second paths. Theabrasive material 235 from the first and second paths can be diverted to disparate destinations, or to the same destination. In other embodiments, however, thecontroller 434 can operate the components along the first and second material paths simultaneously. -
FIG. 5 is a cross-sectional isometric side view of one of thefluidizer assemblies 418, theabrasive valve 423, and a portion of theabrasive delivery conduit 120 according to embodiments of the present disclosure. As shown in the illustrated embodiment, thefluidizer assembly 418 includes a filter holder, distributor coupler, orconnector 502 operably coupled to adistributor 506. Thefluidizer assembly 418 also includes a housing ormanifold 510 coupled to thedistributor 506. Thehousing 510 can comprise a cylindrical member configured to engage an external surface of thedistributor 506. Thehousing 510 can include anair inlet port 511 that is in fluid communication with a correspondingair inlet port 508 in thedistributor 506. - The
filter holder 502 can comprise a cylindrical member having a particle flow passage orinternal bore 503 through which theabrasive material 235 flows during use. As such, theinternal bore 503 of thefilter holder 502 can act as a settling tube configured to receive theabrasive material 235 and be made of an abrasion-resistant material, such as polyurethane or another suitable material. Anupper portion 502 a of thefilter holder 502 can engage a corresponding drop tube 414 (FIG. 4 ), andlower portion 502 b of thefilter holder 502 can engage thedistributor 506. In some embodiments, thefilter holder 502 has a degree of flexibility and thelower portion 502 b can snap or slide onto thedistributor 506. In other embodiments, however, other suitable attachment mechanisms are possible, including threaded and o-ring fastening mechanisms. - The
distributor 506 can also comprise a cylindrical member having a material flow passage orinternal bore 507, and can include anair inlet 511 in fluid communication with air flow passages orconduits 509. Thedistributor 506 can be made of a metal such as aluminum, or a plastic such as polyurethane. In some embodiments, thedistributor 506 is made of an electrically conductive material such as aluminum and electrically grounded to another portion of thefluidizer assembly 418 to disperse any static electricity that can accumulate in theabrasive material 235 as a result of the fluidizing operation. Thedistributor 506 also includes ametering orifice 501 generally axially or centrally aligned with thebore 503. The diameter of themetering orifice 501 is configured to permit theabrasive material 235 to pass through themetering orifice 501 at a desired rate. The diameter of themetering orifice 501 can therefore depend on the dimensions and type of theabrasive material 235, as well as other predetermined parameters of a cutting or other procedure for theabrasive material 235. - According to additional embodiments of the present disclosure, the
fluidizer assembly 418 can also include afilter assembly 513 comprising afilter 514 and ascreen 518 positioned between thefilter holder 502 and thedistributor 506. Thefilter 514 can be a woven polyurethane having openings or holes configured to prevent theabrasive material 235 from passing through thefilter 514. In some embodiments, the holes are approximately 5 microns across. In other embodiments, however, the holes can be larger or smaller than 5 microns. Moreover, thescreen 518 can be a rigid member positioned between thefilter 514 and thefilter holder 502. Further details of thefilter assembly 513 are described in detail below with reference toFIG. 6 . - In operation, the
air inlet 508 of thehousing 510 is connected to one of the air delivery lines 430 (FIG. 4 ) and configured to receive pressurized air from theburst solenoid assembly 424 and/or the fluidizingsolenoid assembly 426. In certain embodiments, the air can be pulsed or flow at a constant rate or pressure. The pulsed air from thesolenoid assemblies air inlet 508 of thehousing 510, and enters theair inlet 511 of thedistributor 506. The air can then travel through theflow passages 509 and through thefilter assembly 513 to fluidize theabrasive material 235 accumulated at or near thefilter assembly 513 to facilitate passage of theabrasives material 235 through themetering orifice 501. Thefilter assembly 513 can prevent the abrasive material from flowing back down theair flow passages 509. -
FIG. 6 is a cross-sectional view of thefilter holder 502,filter assembly 513,distributor 506, andhousing 510 ofFIG. 5 . As shown inFIG. 6 , thescreen 518 includesscreen sections 518 a divided by separatingmembers 518 b extending radially outwardly from acentral opening 521. In other embodiments, thescreen 518 can be a mesh plate without the separatingmembers 518 b. Thescreen sections 518 a can be a of fine mesh, such as a Dutch weave made of stainless steel and having holes of approximately 0.004 inch. In other embodiments, however, the holes can be greater or less than approximately 0.004 inch. - As also shown in
FIG. 6 , theair inlet 508 of thedistributor 506 can be a channel or groove extending circumferentially around an exterior surface of the body thedistributor 506. Moreover, theair flow passages 509 are in fluid communication with theair inlet 508 and extend from theair inlet 508 in a directly generally parallel with a longitudinal axis A of thedistributor 506 to reach thefilter assembly 513. As such, theair inlet 508 can deliver pressurized air through thedistributor 506 to thefilter assembly 513 via theflow passages 509 to fluidize theabrasive material 235 accumulated at the end portion of thedistributor 506. -
FIG. 7A is a cross-sectional isometric side view of thedistributor 506 ofFIG. 6 . As described above, thedistributor 506 can comprise a cylindrical body with acentral bore 507 axially aligned with ametering orifice 501. Thedistributor 506 also includes a plurality offlow passages 509 radially spaced apart from thebore 507 and extending in a direction generally parallel to a longitudinal axis A of thedistributor 506. In some embodiments, thedistributor 506 can include eightflow passages 509 spaced evenly around thedistributor 506. In other embodiments, however, thedistributor 506 can include a greater or lesser number offlow passages 509. Theflow passages 509 can terminate asexit openings 702 at anend portion 704 of thedistributor 506. Theend portion 704 can be configured to directly contact the filter assembly 513 (FIG. 6 ). Theend portion 704 of thedistributor 506 can also include grooves orchannels 706 extending radially outwardly from themetering orifice 506 a to acorresponding exit opening 702. In the illustrated embodiment, eachgroove 706 can have a generally tapered depth from the exterior surface of theend portion 704 that decreases from themetering orifice 506 a as thegroove 706 extends toward thecorresponding exit opening 702. In other embodiments, however, each groove can have a generally constant depth or a depth that tapers in an opposite direction than that shown inFIG. 7A (e.g., that increases as thegroove 706 extends toward the corresponding exit opening 702). In certain embodiments,exit openings 702 can be approximately 0.013 inch in diameter, and thegrooves 706 can be approximately 0.02 inch wide and approximately 0.03 inch deep. In other embodiments, other dimensions and configurations can be used. -
FIG. 7B is an isometric end view of theend portion 704, theexit openings 702, and thegrooves 706 of thedistributor 506 according to embodiments of the present disclosure. In the illustrated embodiment, theend portion 704 includes four equally spaced apart grooves extending radially outwardly from themetering orifice 506 a to individualcorresponding exit openings 702. In other embodiments, however, theend portion 704 can include a greater or lesser number ofgrooves 706. In still further embodiments, other configurations of the grooves and/orexit openings 702 are possible as well. For example, other embodiments of the distributor can have different numbers ofexit openings 702 and/orgrooves 706 than those shown inFIG. 7B . -
FIG. 8A is an isometric view of thecollector 420 ofFIG. 4 , andFIG. 8B is a cross-sectional isometric side view taken substantially alonglines 8B-8B ofFIG. 4 . Referring toFIGS. 8A and 8B together, thecollector 420 includes abody 802 that can be made of an abrasion-resistant material such as polyurethane and having afunnel surface 804 sloping toward anoutlet opening 806. In other embodiments, however, thebody 802 can be made from a metallic material, such as aluminum. Theoutlet opening 806 can be aligned with or otherwise coupled to an abrasive supply conduit for receiving the abrasive material after passing through the fluidizingassembly 418 and themetering orifice 501. Thefunnel surface 804 can have any appropriate slope that facilitates passage of the abrasive material and prevents the abrasive material from collecting. If theabrasive material 235 is allowed to collect, it may reach thewater jet 110 in a non-uniform manner and impair the quality of a cut. - Control Mechanisms and Processes Configured in Accordance with Additional Embodiments of the Disclosure
-
FIG. 9 is an isometric view of the abrasive jet system 401 (FIG. 4 ) including a schematically illustratedcontrol mechanism 900 configured in accordance with embodiments of the present disclosure. In the illustrated embodiment, thecontrol mechanism 900 includesflow meter 904 and apressure gauge 908 associated with theair pressurizer 410. As described above, theair pressurizer 904 is pneumatically connected to theaerators 408, theburst solenoid assembly 424, and thefluidizer solenoid assembly 426 to supply air or other suitable gases to each of these assemblies for fluidizing the corresponding abrasive material. Theair pressurizer 410 can also be pneumatically connected to theabrasive valve 423. Thecontrol mechanism 900 includes acontroller 912 coupled to a programmable logic controller (PLC) 916. ThePLC 916 is configured to receive a “pump on” orgas flow signal 918 and/or an “abrasive on” or abrasive flow signal 920 from thecontroller 912. ThePLC 916 can also be operably coupled to theair pressurizer 410 to transmit various control signals to theair pressurizer 410 during operation. For example, thePLC 916 can transmit afluidizer solenoid signal 924, aburst solenoid signal 926, and/or anabrasive valve signal 923 to theair pressurizer 410. As such, thecontroller 916 and thePLC 916 can control theair pressurizer 410 to convey air flow from thefluidizer solenoid assembly 426 to thefluidizer assembly 418, air flow from theburst solenoid assembly 424 to thefluidizer assembly 418, and/or air flow to theabrasive valve 423 to control abrasive flow. - More specifically, when the
controller 912 issues the “abrasive on” orabrasive flow signal 920, thePLC 916 can in turn instruct theair pressurizer 410 to deliver air to theabrasive valve 423 via anabrasive signal 991. Moreover, when thecontroller 912 issues the “pump on” orgas flow signal 918, thePLC 916 can in turn instruct theair pressurizer 410 to deliver air to theaerators 408 via anaerator signal 990, as well as to deliver air to theburst solenoid assembly 424 viaburst signal 992. In some embodiments, in response to theburst signal 992, theburst solenoid assembly 424 can deliver a strong but transient burst of air to thefluidizer assembly 418 to unsettle theabrasive material 235 that has collected on the filter assembly 513 (FIGS. 4 and 5 ). For example, in one embodiment theburst solenoid assembly 424 can deliver a 25 psi burst of air for approximately 0.5 second to initially loosen or otherwise disturb theabrasive material 235. In other embodiments, however, the initial burst can be at a higher or lower pressure, as well as for a shorter or longer duration. After the initial burst,PLC 916 can instruct thefluidizer solenoid assembly 426 to deliver pulses of air through the same airway as the initial burst via apulse signal 994 to at least partially fluidize the abrasive material. In one embodiment, for example, the pulses of air can be at approximately 1.5 psi at a frequency of approximately 50 Hz. Moreover, the throughput of the pulsed air flow from thefluidizer solenoid assembly 426 can be approximately 10 ft3/h. In other embodiments, however, the pulses of air can be at higher or lower pressures, as well as at higher or lower frequencies. Moreover, and as noted above, in certain embodiments a single air pulse generator or solenoid can provide the various pulses of air flow. For example, a single air pulse generator can provide an initial pulse or burst of air flow to thefluidizer assembly 418, followed by one or more subsequent pulses or bursts of air flow to thefluidizer assembly 418. In certain embodiments, the initial pulse of air can be at a higher pressure and/or for a different duration than the one or more subsequent bursts of air. In other embodiments, however, the initial burst of air can be at the same pressure or a lower pressure than the one or more subsequent bursts of air, as well as for the duration as the individual one or more bursts of air. These routines can be executed by thePLC 916 when thecontroller 912 sends one or more signals to convey abrasive material and/or air flow. Fluidizing the abrasive material with an initial burst followed by sustained pulses causes the abrasive material to evenly or uniformly flow from theabrasive container 230 to the corresponding nozzle assembly 100 (FIG. 3 ). -
FIG. 10 is a flow diagram of a method orprocess 1000 for operating an abrasive jet system in accordance with an embodiment of the disclosure. Theprocess 1000 includes conveying gas through a gas flow passage of a distributor to an accumulation of particles proximate to an end portion of the distributor (block 1002). Conveying gas through the gas flow passage can include at least partially fluidizing the particles proximate to a metering orifice in the end portion of the distributor that is configured to receive particles from the accumulation of particles. In addition, as described in detail above the gas flow passage can exit the end portion of the distributor at a location spaced apart from the metering orifice. In certain embodiments, conveying gas through the gas flow passage includes conveying gas through the gas flow passage at a first pressure and subsequently conveying gas through the gas flow passage at a second pressure that is different than the first pressure. For example, in some embodiments the second pressure can be less than the first pressure. In other embodiments, however, the second pressure can be greater than the first pressure, or the same as the first pressure. Moreover, conveying gas through the gas flow passage at the first pressure can also include conveying at least one pulse of gas at the first pressure and conveying gas through the gas flow passage at the second pressure can also include conveying at least one pulse of gas at the second pressure. In certain embodiments, the first pulse can be for a different duration (e.g., longer or shorter) than the subsequent at least one pulse. In other embodiments, the duration of these pulses can be the same. - According to additional features of the illustrated embodiment, conveying gas through the gas flow passage can include conveying gas through a plurality of gas flow passages that are radially spaced apart from the metering orifice and that extend in a direction generally parallel to a longitudinal axis of the distributor. Additionally, conveying gas through the gas flow passage can further include conveying gas through a screen assembly positioned at the end portion of the distributor. Moreover, in certain embodiments the accumulation of particles can be in an abrasive container and/or in a connector operably coupled to the distributor. For example, the accumulation of particles can be a first accumulation of particles in a connector extending between the distributor and an exit from abrasive container, and the
process 1000 can further include conveying gas through an aerator to a second accumulation of particles proximate to the exit in the abrasive container. - The method also includes conveying particles from the accumulation of particles to a nozzle assembly via the distributor, wherein the particles pass through the metering orifice (block 1004). In certain embodiments, conveying particles from the accumulation of particles comprises opening a particle flow valve downstream from the distributor. After passing through the distributor, the particles can be combined with fluid to form an abrasive jet in a nozzle assembly.
- From the foregoing, it will be appreciated that specific embodiments have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the present disclosure. Those skilled in the art will recognize that numerous liquids other than water, as well as numerous gases other than air, can be used with embodiments disclosed herein. Further, while advantages associated with certain embodiments have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the present disclosure. Accordingly, the inventions are not limited except as by the appended examples.
Claims (26)
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Cited By (13)
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US20120252326A1 (en) | 2012-10-04 |
US9283656B2 (en) | 2016-03-15 |
US9138863B2 (en) | 2015-09-22 |
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